Composite Fabric Material and Apparel Made Therefrom

ABSTRACT

A composite fabric comprises perforated expanded low density polyethylene foam that is mechanically attached to two opposing facing layers, at least one of which outer facing layers is a non-woven material. The mechanical attachment of the perforated expanded low density polyethylene foam layer to the outer facing layers may be through stitching or quilting; through adhesive; or through thermal bonding. The composite fabric provides a textile with exceptional buoyancy, cold-resistant and water-resistant properties and which can be easily handled by conventional textile manufacturing processes.

RELATED APPLICATION

The present invention claims priority of U.S. Provisional PatentApplication Ser. No. 61/148,919 entitled “Composite Fabric Material andApparel Made Therefrom” filed Jan. 30, 2009.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a breathable composite fabric materialused generally in forming apparel.

2. Background Information

The term fabric, as used herein, refers to any material made throughweaving, knitting, crocheting, or bonding (such as non-woven material).The words textile and cloth are used in textile assembly trades (such astailoring and dressmaking) as synonyms for fabric. However some wouldprovide that there are subtle differences in these terms. Somedefinitions of the term textile refer to any material made ofinterlacing fibers, while the term fabric has been defined as referringto any material made through weaving, knitting, crocheting, or bonding,and cloth has been defined as referencing a finished piece of fabric.The terms textile, cloth, fabric are used interchangeably herein. Theterm apparel in this application refers to clothing. Clothing, ingeneral, is worn for safety, comfort, and modesty and to reflectreligious, cultural and social meaning.

As further background for the present application, non-woven is the termused in the textile manufacturing industry to denote fabrics, such asfelt, which are neither woven nor knitted. Non-woven materials aretypically manufactured by putting small fibers together in the form of asheet or web, and then binding them either mechanically, with anadhesive, or thermally such as by applying binder that may be in theform of powder, paste, or polymer melt and melting the binder onto theweb by increasing temperature.

Non-woven materials are often produced from man-made fibers. Twosynthetic polymers dominate the market: polypropylene (PP) andpolyesters (mainly PET). Nonwovens are often application-designated aseither durable or disposable. For example, nonwovens used as house-wrapsto prevent water infiltration are generally considered as durablenonwovens. Nonwovens used as facings on baby diapers are generallyconsidered as disposable or single-use nonwovens. Horticulturalapplications include both frost and insect protection applications.

Textile manufacturing is one of the oldest human industries. It has beensuggested that the oldest known textiles date back to about 5000 B.C.The industrialization of the textile industries is often referenced as aleading or driving force in the industrial revolution. The advancementof textile manufacturing is spurred by new fabrics or fabric compositesthat improve the final product and/or the manufacturing process.

In regards to improvements to textile fabrics, it has been noted in U.S.Pat. No. 4,746,564, which is incorporated herein by reference, thatapparel possessing buoyancy, cold-resistant and waterproof propertiesare highly desirable in a multitude of situations. Military personnelequipped with uniforms and jackets having all of these properties wouldfind them advantageous in a number of situations. For example, asoldier's maneuverability in rough terrain under adverse conditionswould be greatly enhanced by apparel which was both cold-resistant toprotect the wearer from the elements and simultaneously facilitatedcrossing a river or fording a stream due to its buoyant and waterproofproperties. Mountain climbers and hikers would find such garmentssimilarly advantageous, where crossing a river, dealing with a flood, orresisting the cold are all potential encounters. To achieve theirgreatest utility, such garments must not only possess these variousproperties, but they must also be comfortable and not bulky orcumbersome.

It has been noted that water sports enthusiasts would also find suchgarments of particular advantage. Indeed, for many activities, garmentspossessing buoyant, cold-resistant and waterproof properties would beideal and find great utility.

It is known to provide various garments with foamed materials forthermal insulation. U.S. Pat. No. 2,976,539, which is incorporatedherein by reference, discloses a thermally-insulated garment having anexpanded, closed-cell cellular material as a lining, preferablypolyvinyl chloride. The garment is thick and cumbersome and does notpossess sufficient buoyancy to support a person's weight in water.

Similarly, U.S. Pat. No. 3,511,743, which is incorporated herein byreference, discloses a thermal insulation laminate for space and divingsuits whose core is an open or closed-cell sponge or foam. A fluidimpermeable rubber or plastic skin is necessary. The laminate givesmoderate mobility, but is still fairly cumbersome and does not havesufficient buoyancy to serve as a life-saving device.

Polyethylene foams have been suggested as insulation or fillers for liferafts and jackets. U.S. Pat. No. 3,067,147, which is incorporated hereinby reference, suggests a low density polyethylene foam for such apurpose which is processed with 1,2-dichlorotetrafluoroethene as afoaming or blowing agent. The polyethylene and blowing agent are heatedunder pressure and explosively extruded into the atmosphere to form anexpanded cellular mass. The product is bulky and cumbersome when used inpractice.

Similarly, U.S. Pat. No. 3,819,543, which is incorporated herein byreference, discloses molded chlorinated, cross-linked polyethylene foamfor use in producing floats and linings for clothing. Various knownblowing and cross-linking agents are suggested for use by thisreference. The molded products are thick and cumbersome.

U.S. Pat. Nos. 4,746,564 and 4,952,352, which are incorporated herein byreference, attempted to address these deficiencies and described a thin,lightweight material for use as a liner for garment and outdoorequipment which possesses a combination of superior buoyancy,cold-resistant and water-resistant properties, without hampering themobility of the wearer. However, the superior properties exhibited withthe fabric disclosed in these patents could not be fully utilized asthese fabrics required special handling and skill in the apparelmanufacturing, which greatly limited their introduction into, andadoption by, the textile industry at large. A further drawback withthese solutions was essentially a complete lack of moisture vaportransmission or permeability (also generally referred to as“breathability”).

It is an object of the present invention to address the deficiencies ofthe prior art discussed above and to provide an efficient breathablecomposite fabric material used generally in forming apparel that can beproduced in a cost effective manner and can be easily utilized in thetextile industry.

SUMMARY OF THE INVENTION

The various embodiments and examples of the present invention aspresented herein are understood to be illustrative of the presentinvention and not restrictive thereof and are non-limiting with respectto the scope of the invention. The present invention provides abreathable composite fabric that comprises a perforated expanded lowdensity polyethylene foam layer that is mechanically attached to twoopposing nonwoven facing layers.

According to one non-limiting embodiment of the present invention, themechanical attachment of the perforated expanded low densitypolyethylene foam layer to the outer facing layers is through stitchingor quilting. In another nonlimiting aspect of the invention themechanical attachment of the perforated expanded low densitypolyethylene foam layer to the outer facing layers is through adhesive.In a further nonlimiting aspect of the invention the mechanicalattachment of the perforated expanded low density polyethylene foamlayer to the outer facing layers is through thermal bonding.

According to one non-limiting embodiment of the present invention, theexpanded low density polyethylene foam layer is about 10-30 mils thick,generally around about 0.5 millimeters thick or about 20 mils. Accordingto one non-limiting embodiment of the present invention, the outerfacing layers are each about 2.5-10 mils thick. According to onenon-limiting embodiment of the present invention, the composite fabricis about 15-50 mils thick, generally about 30-35 mils or about 0.80millimeters.

According to one non-limiting embodiment of the invention theperforations in the expanded low density polyethylene foam layer areconical. The perforations are provided to provide a desiredbreathability to the composite fabric while maintaining a meaningfulwater resistance property. The perforations may be considered microperforations as they maintain water resistance properties, but aresufficient to provide the desired breathability.

The composite fabric of the present invention can be easily incorporatedinto many types of apparel by coupling the composite fabric with anyconventional outer textile fabric. The fabric liner of the presentinvention can form an effective and efficient inner drop liner for ajacket. In one non limiting aspect of the present invention thecomposite fabric is used as a liner for a ice fishing suit, Three layersof the composite fabric of the present invention are provided as thelining in an ice fishing suit, namely a jacket and bib. Thisconstruction provides buoyancy to the user sufficient to keep the userafloat, and the suit maintains a desirable breathability to maintain asufficient comfort level to the user, and provides an exceptionally highthermal insulation property necessary for this application, all in avery lightweight apparel design.

These and other advantages of the present invention will be clarified inthe description of the preferred embodiments taken together with theattached figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross section of a composite fabric in accordancewith one embodiment of the present invention; and

FIG. 2 is a schematic enlarged front view of the composite fabric ofFIG. 1; and

FIG. 3 is a schematic cross section of a composite fabric in accordancewith another embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In summary, the present invention relates to a light weight, breathable,composite fabric 10 with high thermal insulating properties which isprovided with three integral sections or layers 20, 30 and 40 asdescribed below. The composite fabric 10 according to the presentinvention will provide a textile with exceptional buoyancy,cold-resistant and water-resistant properties while providing acceptablebreathability to the composite fabric and providing a fabric which canbe easily handled by conventional textile manufacturing processes.

The composite fabric 10 has, in one embodiment, a total thickness ofabout 30-35 mils or about 0.80 millimeters, and generally has a totalthickness of 15-50 millimeters. The composite fabric 10 can be cut toshape and attached to essentially any outer textile fabric in anyconventional fashion, such as stitching or the like. The compositefabric 10 can form an efficient and effective inner drop liner forapparel. The composite fabric has a high thermal insulating value with a“Clo” value of approximately 2.0. The insulation of clothes are oftenmeasured with the unit “Clo”, where 1 Clo=0.155 m²K/W. For background,Zero (0) Clo corresponds to a naked person, while One (1) Clocorresponds to a person wearing a typical business suit.

The first or front outer facing layer 20 of the composite fabric 10 is areinforcing nonwoven material, such as formed from polyester orpolyethylene. The thickness of the nonwoven facing layer 20 isapproximately 2.5-10 mils. The outer facing layer 20 can be formedeffectively of a wide variety of nonwoven material that provides themoisture vapor transition needed for most apparel applications.

The third or rear outer facing layer 30 of the composite fabric 10 is areinforcing nonwoven material substantially identical to layer 20 and isopposed from the layer 20 as shown.

The second or intermediate layer 40 is a perforated foam layer 40,specifically, expanded low density polyethylene foam that ismechanically attached to the outer facing layers 20 and 30, such asthrough an attachment mechanism 50.

Low density polyethelene (LDPE) is a thermoplastic which is defined by adensity range of 0.910-0.940 g/cm³. It is un-reactive at roomtemperatures, except by strong oxidizing agents. It is known as beingquite flexible, and tough. LDPE has more branching (on about 2% of thecarbon atoms) than high density polyethylene (HDPE). The LDPE moleculesare less tightly packed and less crystalline than HDPE because of theside branches, and thus its density is lower.

The low density polyethylene foam layer 40 can preferably be formed ofInsultex® brand low density polyethylene foam sold by Innovative Designsof Pittsburgh. This type of low density polyethylene foam be made, forexample, by a process comprising mixing low density polyethylene with ablowing agent, a surface activation agent and, preferably, a separationagent, heating the resultant mixture to form a softened mass, raisingthe temperature of the softened mass to gasify the blowing agent forfoaming and expanding the cells of the polyethylene, reducing thetemperature of the foamed and expanded polyethylene to partially shrinkand harden the polyethylene cells, introducing a gaseous blowing agentinto the polyethylene mass to cause additional foaming and expansion ofthe polyethylene cells, cooling the mass to a temperature suitable forcutting, cutting and heating the mass to a temperature suitable forextruding, extruding the mass, forming the mass into a sheets, andcooling the sheet or tube for a setting time to form a low densitypolyethylene sheet characterized by superior buoyancy and thermalresistance. A process for forming such foam is described, for example,in U.S. Pat. Nos. 4,952,352 and 4,746,564 which are incorporated hereinby reference.

A further detailed process for forming such expanded polyethylene foamfor layer 40 is described in Korean Patent Registration Number10-0428429 that issued Mar. 29, 2004. This is a more precise descriptionof the formation of the most recent version of the Insultex® brandproduct which has been used to form the composite fabric of the presentinvention.

The process as described may be summarized as including the steps ofadding a low density polyethylene (LDPE) with dual co-blowing agents, asurfactant and a release agent to form an LDPE composition. The LDPEcomposition is then mixed with a flame retardant and antimony oxide in ahopper container. The mixed composition is next heated in the hopperpast the effective gasification temperature of the dual blowing agents(which is described as generally 120-150° C.) to form expanded beads andthe hopper is then cooled. Following the expansion and cooling, thehopper is heated to an extraction temperature and the expanded productis extracted and allowed to stand at room temperature for a settingperiod. The expanded product can then be formed into sheets to form thelayer 40 with the perforations 44 as described below. The foam layer 40should be about 0.5 mils or about 20 mils in thickness, generallybetween 10 and 30 mils.

The third or intermediate LDPE foam layer 40 is a perforated, wherein aseries of equally spaced perforations 44 extend through the layer 40.The perforations 44 are significant in making the composite fabricbreathable for the comfort of the user. The size of the perforations 44,generally between 0.02 and 0.05 millimeters, may make the perforationsconsidered to be micro-perforations. The micro-perforations make thecomposite fabric breathable while still maintaining water resistance(although no longer water proof due to the perforations and theassociated vapor moisture transmission property). The breathability ofthe composite fabric 10 is a critical aspect of the present invention.The specific breathability can be increased or decreased by increasingor decreasing the perforation 44 density (i.e. the number ofperforations 44).

The perforations 44 can be conical. However, cylindrical perforationsfor perforations 44 would also be acceptable. The perforations 44 can beformed on layer 40 through a perforation roller which has a series ofperforation pins thereon. For the conical shaped perforations as shownthe pins would have a shape similar to the final desired shape. Thelayer 40 can be perforated before the composite fabric 10 is assembled,or the perforations 44 can be made after the composite fabric 10 isassembled with the perforations extending through at least one andlikely both outer facing layers 20 and 30. Alternatively, the layer 40may be perforated after only one of the facing layers 20 or 30 isattached to the layer 40.

The attachment mechanism 50 for coupling the layers 20, 30 and 40 may bestitches in a quilting pattern as shown in FIGS. 1-2. The stitchingmaterial is conventional and the stitching pattern (quilting pattern)can be varied as desired. For example the standard diamond pattern canbe increased in size or decreased, or replaced with a scalloped patternfor aesthetic or structural reasons.

Alternatively the layers 20, 30 and 40 may be bonded together throughadhesives, whereby the adhesive forms the attachment mechanism 50 asshown in FIG. 3. The adhesive would have a thickness of about 1 mil,typically less than 3 mils, and can be formed of any of many standardadhesives. The adhesive layers may be across the entire surface in alamination adhesive type arrangement or in a selected pattern such assimilar to the stitching pattern disclosed above.

Alternatively the layers 20, 30 and 40 may be bonded together throughthermal bonding, wherein the attachment mechanism 50 is formed by bondedelements of the respective layers. This is still considered a mechanicalattachment within the meaning of this application. If utilized, it wouldbe preferred that the melting temperature of a component of the layers20 and 30 be lower than the layer 40 for the operation of this bonding.If the layer 40 melted prior to the outer layers 20 and 30 during thisattachment it could detrimentally effect the physical properties of theresulting composite material 10.

Other mechanical attachment may be possible such as ultrasonic welding.The keys to considering acceptable attachment techniques is one thatsecurely fastens the layers together in a structure that can be easilymanipulated in conventional textile operations (e.g., it can be easilycut and sewn). Further the attachment process cannot negatively affectthe desired properties of breathability, water resistance, buoyancy, andthermal insulation.

The composite fabric of the present invention can be easily incorporatedinto many types of apparel by coupling the composite fabric with anyconventional outer textile fabric. The composite fabric 10 of thepresent invention is far better suited to conventional textilemanufacturing techniques than prior expanded low density foam fabrics.

In one non limiting aspect of the present invention the composite fabricis used as a liner for a ice fishing suit, Three layers of the compositefabric of the present invention are provided as the lining in an icefishing suit, namely a jacket and bib. This construction providesbuoyancy to the user sufficient to keep the user afloat, and the suitmaintains a desirable breathability to maintain a sufficient comfortlevel to the user, and provides an exceptionally high thermal insulationproperty (i.e. rated for sub-zero applications) necessary for thisapplication, all in a very lightweight apparel design (i.e. the jacketis has the general bulk and weight of a “light weight” jacket).

Another application using the present invention is using the compositematerial 10 with an outer silk layer which results in an extremely highinsulating material with very high workability and drape-abilitycharacteristics.

Another embodiment of the present invention for silk apparelapplications is formed effectively by replacing one of the facing layers20 or 30 with a silk layer to form a distinct silk composite materialformed of a non-woven layer 20 or 30 with the intermediate layer 40 andan opposite outer silk layer. This alternative silk composite materialis generally for outerwear formed of silk. In conventional silk fabrics,adding insulating layers will detrimentally compromise the“drape-ability” of the resulting fabric. This modified silk composite ofthe present invention effectively addresses these concerns.

Whereas particular embodiments of the invention have been describedabove for purposes of illustration, it will be evident to those skilledin the art that numerous variations of the details of the presentinvention may be made without departing from the spirit and scope of thepresent invention.

1. A composite fabric comprising: a perforated expanded low densitypolyethylene foam layer; and a pair of outer facing layers of nonwovenmaterial, wherein the perforated expanded low density polyethylene foamlayer is mechanically attached to two opposing nonwoven outer facinglayers.
 2. The composite fabric according to claim 1 wherein themechanical attachment of the perforated expanded low densitypolyethylene foam layer to the outer facing layers is through stitching.3. The composite fabric according to claim 1 the mechanical attachmentof the perforated expanded low density polyethylene foam layer to theouter facing layers is through adhesive.
 4. The composite fabricaccording to claim 1 the mechanical attachment of the perforatedexpanded low density polyethylene foam layer to the outer facing layersis through thermal bonding.
 5. The composite fabric according to claim 1wherein the expanded low density polyethylene foam layer is about 10-30mils thick.
 6. The composite fabric according to claim 5 wherein themechanical attachment of the perforated expanded low densitypolyethylene foam layer to the outer facing layers is through stitching.7. The composite fabric according to claim 1 wherein the expanded lowdensity polyethylene foam layer is about 0.5 millimeters thick.
 8. Thecomposite fabric according to claim 7 wherein the mechanical attachmentof the perforated expanded low density polyethylene foam layer to theouter facing layers is through stitching.
 9. The composite fabricaccording to claim 1 wherein the outer facing layers are each about2.5-10 mils thick.
 10. The composite fabric according to claim 9 whereinthe composite fabric is about 15-50 mils thick.
 11. The composite fabricaccording to claim 1 wherein the composite fabric is about 0.8millimeters thick.
 12. The composite fabric according to claim 1 whereinthe perforations in the expanded low density polyethylene foam layer areconical.
 13. A composite fabric comprising: A first nonwoven outerfacing layer; An expanded low density polyethylene foam layer adjacentthe first nonwoven layer and having a plurality of micro-perforationsthrough the expanded low density polyethylene foam layer; A second outerfacing layer adjacent the expanded low density polyethylene foam layer;and Stiches mechanically fastening the first nonwoven outer facinglayer, the expanded low density polyethylene foam layer and the secondouter facing layer.
 14. The composite fabric according to claim 13wherein the composite fabric is about 0.8 millimeters thick.
 15. Thecomposite fabric according to claim 13 wherein the expanded low densitypolyethylene foam layer is about 0.5 millimeters thick.
 16. Thecomposite fabric according to claim 13 wherein the perforations in theexpanded low density polyethylene foam layer are conical.
 17. An articleof apparel comprising: A) At least one outer textile fabric; and B) Aninner liner comprising a composite fabric, the composite fabricincluding i) a perforated expanded low density polyethylene foam layer;and ii) a pair of outer facing layers, wherein at least one of which isformed of a nonwoven material, and wherein the perforated expanded lowdensity polyethylene foam layer is mechanically attached to two opposingouter facing layers.
 18. The article of apparel according to claim 17wherein the apparel is a jacket.
 19. The article of apparel according toclaim 17 wherein the composite fabric is about 0.8 millimeters thick.20. The article of apparel according to claim 17 wherein the expandedlow density polyethylene foam layer is about 0.5 millimeters thick.